Delphi BTS Series User manual

Connector 6-way
for 150/280 Terminals (BTS and similar)
sealed
Assembly at harness plant
REV 04 - May 2012
ADI-15458155-2
D

2/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
TABLE OF CONTENTS
The information contained in these assembly instructions is subject to alteration without prior notice and does not
represent any obligation on the part of DELPHI. All information is correct at the time of releasing. Reprinting or translation
is not permitted without written permission from DELPHI. 

Copyright 2012 DELPHI. All rights reserved.
...............................................................…..….…........………................... 3
................................................................................…….......….………...................... 4
................................................................................……......…................................ 5
................................................................................…………........…...... 6,7
..............................………….......…..…............................................................. 8
...................................................................... 8
.................................................................... 9
...................................................................................... 10
....................................................................................................... 11
...................................................................................... 12,13
......................................................................................... 14,15
...................................................................….16
................................................ 17, 18, 19, 20
..............................………….......…..…....................................................... 21
.................................................................................... 22, 23
.............................................................................. 24, 25
................................................................................................. 26
.................................................................. 27
................................................................. 28
………………………………………………………..….….................................……….. 29, 30
………………………………………………………………………..….…................................….. 31
……………………………………………………………………….……............................…...….. 32
Components (exploded view)
List of components
View of versions
Delivery status, descriptions
ASSEMBLY SEQUENCE:
step 1: inserting Female Terminals 150
step 2a: inserting Female Terminals 280
step 2b: inserting Cavity Plug
step 3: locking SL
step 4: locking Cable Caps
step 5: strapping cables
step 6: electrical and mechanical tests
Requirements for Connector 6-way testing
DISASSEMBLY SEQUENCE:
step D-1: removing cable tie
step D-2: removing Cable Caps
step D-3: unlocking SL
step D-4: removing Female Terminals 280
step D-5: removing Female Terminals 150
Table of tools
Packaging
Revisions

3/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
EXPLODED VIEW
Female Terminal 150
(BTS and similar)
Female Terminal 280
(BTS and similar)
Receptacle Housing 6-way
PART-NO. see page 4
CPA (optional)
See page 4
Cavity Plug
Pictures used in this Assembly Manual and original parts may differ in some details,
This difference has no influence on the assembly process .
ATTENTION.
Optional Cable Caps are not available

4/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Terminal 280 (BTS and similar): max. 2
LIST OF COMPONENTS
Component
(pre-assembled)
DELPHI
Part-No.
Housing 6-way 15458151 (mixed 1.5/2.8 without CPA, Black) 1
15458152 (mixed 1.5/2.8 without CPA, Grey)
15458153 (mixed 1.5/2.8 without CPA, Blue)
15458163 (mixed 1.5/2.8 with CPA, Black)
15458164 (mixed 1.5/2.8 with CPA, Grey)
15458165 (mixed 1.5/2.8 with CPA, Blue)
(only 1.5 line without CPA, Yellow)
15440054 (only 1.5 line without CPA, Green)
15440055 (only 1.5 line without CPA, Brown)
15458160 (only 1.5 line with CPA, Yellow)
15458161 (only 1.5 line with CPA, Green)
15458162 (only 1.5 line with CPA, Brown)
15427148 (2 cavities closed without CPA)
15458159 (2 cavities closed with CPA)
Terminal 150 (BTS and similar): max. 6
Amount

5/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
VIEW OF VERSIONS

6/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
DELIVERY STATUS, PART DESCRIPTIONS
PART DESCRIPTIONS
DELIVERY STATUS

7/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
DELIVERY STATUS, PART DESCRIPTIONS
CPA locked in pre-
position-windows
CPA locked in end-
position-windows
OK
NOK
CPA DELIVERY STATUS

8/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Step completed.
Insert the Terminals 150 (or Cavity Plug for 4-way version - see page 10) through the cavities
by respecting the Terminal polarization.
INSERTING TERMINAL 150
Correctly locked
locking arm
(one of two)
Validated up to 4 cycles max for
insertion/removing Terminal.
1

9/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
INSERTING TERMINAL 280
Correctly locked
locking arm
(one of two)
Insert the Terminals 280 through the 6-way cavities by respecting the Terminal polarization
(make use of housing shapes similar to terminal crimping area to find the right orientation).
Only two positions
of the Terminal are
correct !
Crimp-similar
shapes
Validated up to 4
cycles max for
insertion /
extraction
Terminal.
2a
Step completed.

10/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
INSERTING CAVITY PLUG
Insert the Cavity Plug into all empty cavities.
Blank cavities
Correctly inserted
Cavity Plug
Connector 4-way version
(2 blank cavities)
Cavity Plug:
210A015019
9628693180
2b
Step completed.

11/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
NOTE: Validated for 10 cycles opening and closing SL!
Push the SL until it is correctly locked in the end position.
LOCKING SL
SL in locked position
Closing force of SL:
Terminals in right position
15 < F < 40 N
Terminals in wrong position
F > 100 N
Validated up to 10 cycles max for
opening and closing SL
SL in pre-position
Position of the SL closing
mechanism
3
Step completed.

12/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Insert first the shorter locking arm (arrow 1), and press after in the opposite side (arrow 2) to
lock the Cable Cap TYPE A ....
LOCKING CABLE CAP
shorter
locking arm
longer
locking arm
ATTENTION !
CABLE CAP IS NOT AVAILABLE
OPTIONAL (Cable Cap TYPE A)
4a
Step completed.

13/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
LOCKING CABLE CAP
... or Cable Cap TYPE B
shorter
locking arm
longer
locking arm
OPTIONAL (Cable Cap TYPE B)
4b
ATTENTION !
CABLE CAP IS NOT AVAILABLE
Step completed.

14/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
The cables are tightening ...
STRAPPING CABLES
ATTENTION !
CABLE CAP IS NOT AVAILABLE
OPTIONAL (Cable Cap TYPE A)
5a
Step completed.

15/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
STRAPPING CABLES
OPTIONAL (Cable Cap TYPE B)
ATTENTION !
CABLE CAP IS NOT AVAILABLE
5b
Step completed.

16/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Apply the electrical test. Measurement and assembly controls
ELECTRICAL TEST
6

17/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Test Probes
Test ProbesTest Probes
Test Probes1
11
1
The maximum Force to 1.5 and 2.8 Terminals is 15 NMaximum contact force1.4
Test probe dimensions for 1.5 and 2.8 terminals is 0.6 x 4mm FLAT
HEAD;
TOLERANCE +/ 0,02 mm
Head dimensions
1.3
Flat head RectangleHead shape of Test
probe
1.2
Position of Test probes1.1
Data
DataData
DataItem
ItemItem
ItemPosition
PositionPosition
Position
REQUIREMENTS FOR TESTING CONNECTOR 6-WAY

18/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
less than 23.08
less than 23.08less than 23.08
less than 23.08 mm (terminal 1.5) in reference to the Reference Plane
(see position 1.1)
Tightening area and position
of connector
2.2
?Clamping Force2.3
Data
DataData
DataItem
ItemItem
ItemPosition
PositionPosition
Position
Coding control required.
Coding control via mechanical coding in test holder.
If version 15458150 (Black) or 15427143 (Violet) is used in the
production, a greyscale sensor is needed distinguish the version
because the coding is identically.
Coding control
2.1
Connector
ConnectorConnector
Connector2
22
2
Sicma test probeDesign of test probe
connection
1.7
Dimension of locked and
unlocked terminal
1.6
from 23.08
from 23.08 from 23.08
from 23.08 mm (terminal 1.5) to 23.88
to 23.88to 23.88
to 23.88 mm (terminal 2.8) in reference
to the Reference Plane (see position 1.1)
Position tolerance of
terminal cavity of
correctly seated terminal
1.5
REQUIREMENTS FOR TESTING CONNECTOR 6-WAY

19/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Position
PositionPosition
Position Item
ItemItem
Item Data
DataData
Data
2.4 Position of connector fixing
The positioning of the connector fixing in the test holder is on the
left and right side of the connector on the symmetry middle of the
connector. Clamping only on the housing.
2.5 Position of switch probe for
connector detection in holder
The positioning of the connector detection in the test holder
symmetry middle of the connector.
A = 11,25 mm, Switch Pin Head = Ø 3 mm
3
33
3 Additional test
Additional testAdditional test
Additional test
3.1 Control Secondary Lock (Step1)
Check on precense and open position of SL.
The positioning of the SL detection in the test holder symmetry
middle of the connector.
A = 2,25 mm, Switch Pin Head = Ø 1 mm
3.1.1 Define maximum force to close
SL 15 N < F < 40N
3.1.2 Define maximum travel way to
close SL 3,5mm
A
A
REQUIREMENTS FOR TESTING CONNECTOR 6-WAY

20/32
Assembly Manuals
Connector 6-way for 150/280 Terminals – harness plant assembly
REV 04 – May 01, 2012
ADI-15458155-2
delphi.com/connectors
Position
PositionPosition
Position Item
ItemItem
Item Data
DataData
Data
3.1.3 Position of the SL closing
mechanism see page
11
1111
11
3.1.4 Control Secondary Lock on close
(Step5) The locking position of the PLR (SL) is checked by the end position of the SL closing mechanism
3.2 Leak test Leak Test required
3.2.1 Test parameter Test realization = Pressure
Nominal Pressure = 300m Bar
Limits Good = 200 mBar < P < 500 mBar
3.3 Presence and position check of
cable tie Depend on conditions.
3.4 CPA presence check
Is required when option is assembled.
3.4.1 Position of CPA presence check
Position in prototype holder (new standard):
Symetry middle of connector from top.
Point 1 CPA open
Point 2 CPA presence
A= 13,9 mm
B=18,25 mm
C=4mm
Switch probe head Ø 2 m
4
44
4 Test
TestTest
Test parameter
parameterparameter
parameter
4.1 Step 1 Check SL on open
4.2 Step 2 Execute push test
4.3 Step 3 Check connection
4.4 Step 4 Close SL
4.5 Step 5 Control if SL is closed
4.6 Step 6 Execute leak test
4.7 Step 7 Check lock of cable tie
4.8 Step 8 (optional) Check color of SL to distinguish Black/ Violet SL
4.9 Step 9 (optional) Check presence and position of CPA
4.10 Step 10 (optional) Check Cover
A
B
C
REQUIREMENTS FOR TESTING CONNECTOR 6-WAY